Solid-core panel incorporating decorative and/or functional material

ABSTRACT

A panel includes a fiberglass substrate encapsulating an aesthetic material. The fiberglass substrate and the aesthetic material are both impregnated with resin to form the solid-core of the panel. The solid-core panel can be manufactured by arranging multiple layers of a fiberglass material between multiple plates, interleaving aesthetic material between at least two of the layers of fiberglass material, applying resin to the multiple layers of fiberglass material and the aesthetic material, and then allowing the combination of the resin, multiple layers of fiberglass material, and the aesthetic material to cure between the plates, forming a solid-core panel encapsulating the aesthetic material.

RELATED APPLICATIONS

This application is a divisional application of and claims priority topending U.S. patent application Ser. No. 12/726,080, filed Mar. 17,2010, all of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates generally to solid-core panels that incorporateaesthetic material.

BACKGROUND

Transparent or translucent glass panes are often utilized to allow lightto illuminate residential and commercial environments. There are manytechniques that designers have utilized to enhance the aesthetics ofthese glass panes. For instance, some glass pane manufacturers bevel ortexturize surfaces of panes to render them opaque or to provide adesired design. Another aesthetic-enhancement technique involvesadhering decorative window film to smooth surfaces of the glass panes.

Some designers have attempted to replace glass panes, for example, indoors and windows, with plastic or acrylic panels that include adecorative paper or tissue. These plastic panels are produced bylaminating two plastic sheets or resin-based panes around the decorativepaper or tissue, for example, with glue or other adhesive. The resultinglaminate panel is often further enclosed with additional plastic sheetslaminated to the exterior of the panel.

While laminated panels allow the decorative paper or tissue to be viewedthrough the plastic layers, the process of layering multiple sheetsaround the decorative material can provide poor aesthetics, i.e., due tooptical distortion of the decorative paper caused by the layering oradhesive, or due to unintentional incorporation air bubbles between thevarious layers. Since these plastic panels are laminated, their layerstend to separate over time, allowing water and mold to infiltratebetween the layers and into the decorative paper or tissue. Thelaminated panels are further limited to incorporating only flat paper ortissue capable of adhering to the laminating adhesive.

DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are block diagrams of an example solid-core panelincorporating aesthetic material according to embodiments of theinvention.

FIG. 1D is a block diagram showing an example aesthetic materialincorporated into the solid-core panel shown in FIGS. 1A-1C.

FIGS. 2A and 2B are block diagrams of an example solid-core panelincorporating decorative material according to embodiments of theinvention.

FIGS. 3A and 3B are block diagrams of an example solid-core panelincorporating decorative material according to embodiments of theinvention.

FIGS. 4-7 are flow diagrams showing example exploded side-views of thesolid-core panels according to embodiments of the invention.

FIGS. 8-9 are flowcharts illustrating example embodiments for creatingthe solid-core panels according to embodiments of the invention.

DETAILED DESCRIPTION

As described above, since previous panels incorporating decorativematerial are produced through a lamination process—with multipletransparent or translucent sheets are adhered or affixed together arounda decorative paper or tissue—the overall aesthetics of the panels sufferdue to optical distortion from the layering and lamination,unintentional incorporation of air bubbles, and the eventual layerseparation and infiltration of water, mold, and/or particulates. Byencapsulating aesthetic or decorative materials into a solid-core panel,the integrity of the aesthetic or decorative material in the panel canbe maintained. Embodiments of the solid-core panels and multipleprocesses for producing the solid-core panels are shown and describedbelow in greater detail.

FIGS. 1A-1B are block diagrams of an example solid-core panel 100incorporating aesthetic material 120 according to embodiments of theinvention. Referring to FIGS. 1A and 1B, a side-view and a top-view of asolid-core panel 100 are shown. The solid-core panel 100 includes aresin and fiberglass substrate 110 that encapsulates aesthetic ordecorative material 120, which can render the aesthetic material 120viewable through at least one of the top or bottom surfaces of thesolid-core panel 100.

The solid-core panel 100 can be a flat-rectangular panel, as shown inFIGS. 1A and 1B, or the solid-core panel 100 can take on any shape orcontour, for example, by having exterior surfaces formed in any numberof shapes. The surfaces of the solid-core panel 100 can have variousfinishes, such as gloss, smooth, matte, or textured finishes. Thesurfaces can also be stamped or otherwise contoured, for example, with arelief-technique. Embodiments of the production of the solid-core panel100 will be described below in greater detail.

The aesthetic material 120 can be a relatively planar material, forinstance, decorative paper, film, fabric or other woven material,tissue, or other organic material. In some embodiments, the aestheticmaterial 120 can provide additional functionality beyond aesthetics, forexample, the aesthetic material 120 can be a solar fabric orsolar-metalized material, such as solar cells, which will be describedbelow in greater detail. The aesthetic material 120 can also be utilizedto help reinforce the panel, for example, when the aesthetic material isa carbon fiber mesh or other relatively rigid material.

Although FIGS. 1A and 1B show the aesthetic material 120 assubstantially level or parallel with at least one of the surfaces of thesolid-core panel 100, in some embodiments, the aesthetic material 120can be positioned or arranged in non-parallel orientation to providediffering aesthetics to the panel or to provide varied functionality.Because the panel has a solid-core, and not laminated, the aestheticmaterial 120 can be located anywhere within the solid-core panel 100. Insome embodiments, the aesthetic material 120 can be positioned closer toone surface of the solid-core panel 100 to enhance the aesthetics orfunctionality of the solid-core panel 100. In other embodiments, theaesthetic material 120 can be positioned closer to the middle of thesolid-core panel 100 to further embed the aesthetic material 120 in thesolid-core panel 100.

The resin and fiberglass substrate 110 can be a combination of afiberglass base that is impregnated or saturated with resin or aresin-based product. The resin or resin-based product can be a clear ortranslucent polyester-based resin. Both the fiberglass and the resin canbe transparent or translucent, and possibly include pigments or dyesthat tint or color the resin and fiberglass substrate 110 in thesolid-core panel 100.

The aesthetic material 120 can also be impregnated or saturated with theresin or the resin-based product. The impregnation or saturation of thefiberglass with resin can “wet out” the fiberglass, as well as theaesthetic material 120, giving the fiberglass and the aesthetic material120 a “wet” look. The impregnation or saturation of the aestheticmaterial 120 can also preserve the material and protect the aestheticmaterial 120 from the elements, such as temperature variances, moisture,humidity, and air. Since the solid-core panel 100 encapsulates theaesthetic material 120, the solid-core panel 100 can be utilized anyplace glass or other transparent or translucent panels are used incommercial, industrial, or residential environments.

Surfaces of the resin and fiberglass substrate 110 can include anintegrated protective coating 112 and 114. The protective coating 112and 114 can be a combination of a polyurethane-based material, a clearcoat polymer, or a gel coat polymer, and resin, and possibly thefiberglass. The protective coating 112 and 114 can provide a rigidsurface to the solid-core panel 100, which reduces bowing or warping ofthe solid-core panel 100 and helps prevent scratching, chipping, andfracturing of the solid-core panel. As will be described below ingreater detail, the protective coating 112 and 114 can be applied priorto or substantially concurrently with the application of the resin, orcan be applied after the resin has begun curing, for example, in sprayedapplication.

FIG. 1C is a block diagram of another example solid-core panel 150encapsulating multiple levels of material 170 according to embodimentsof the invention. Referring to FIG. 1C, a side-view of the solid-corepanel 150 is shown. Solid-core panel 150 is similar to the solid-corepanel 100 described above, except the solid-core panel 150 incorporatesmultiple levels of encapsulated material 170A and 170B.

The encapsulated material 170A and 170B can be similar to the aestheticmaterial 120 incorporated into solid-core panel 100, albeit in multiplelayers. The ability to provide multiple layers of material 170A and 170Ballows for many different applications. For instance, the use ofmultiple material layers can provide a three-dimensional aesthetic tothe solid-core panel 150. The multiple material layers can also providediffering visual effects from each viewable side of the panel. Forinstance, as shown in FIG. 1C, material 170A can be primarily viewablefrom the top side of the solid-core panel 150, while material 170C canbe primarily viewable from the bottom side of the solid-core panel 150.

In many applications, the solid-core panel 150 can have a predominateaesthetic-side, i.e., the side of the panel that is primarily viewable,while the aesthetics of the other side are not as important. In thesecases, the material closest to the aesthetic-side can be a decorativematerial, while the material on the other side can provide someadditional functionality. For instance, the functional material can besolar cells capable of producing energy, a solar fabric to dispersedirect sunlight, a material that can add rigidity or strength to thepanel 150, or even additional electronics, such as back lighting. Inother applications, the encapsulated material 170A and 170B can both befunctional materials, such as solar cells on both sides of thesolid-core panel 150.

Although FIG. 1C shows the encapsulated materials 170A and 170B assubstantially level or parallel with the surfaces of the solid-corepanel 150, in some embodiments, the encapsulated materials 170A and 170Bcan be positioned or arranged in non-parallel orientation to providediffering aesthetics to the panel or to provide varied functionality.Because the panel has a solid-core, and not laminated, the aestheticmaterial 120 can be located anywhere within the solid-core panel 100. Insome embodiments, the aesthetic material 120 can be positioned closer toone surface of the solid-core panel 100 to enhance the aesthetics orfunctionality of the solid-core panel 100. In other embodiments, theaesthetic material 120 can be positioned closer to the middle of thesolid-core panel 100 to further embed the aesthetic material 120 in thesolid-core panel 100.

FIG. 1D is a block diagram showing an example aesthetic material 120 or170A-170B incorporated into the solid-core panels 100 and 150 shown inFIGS. 1A-1C. Referring to FIG. 1D, as discussed above, many materialscan be encapsulated within the solid-core panels 100 and 150, includinga solar fabric 130 described in FIG. 1D. The previous laminated panelsdescribed above, could not incorporate solar fabrics or other fabrics,as the glue or adhesive utilized in the lamination process did notadhere to solar fabrics.

The solar fabric 130 can be comprised of a fabric mesh 132, whichcreates openings 134 that allow light to pass, while diffusing directsunlight and some of the radiant heat. The fabric bands can be made ofnatural or man-made materials. The fabric mesh 132 can include fabricbands that are interleaved or woven into various patterns, such as abasket-weave pattern shown in FIG. 1D.

FIGS. 2A and 2B are block diagrams of an example solid-core panel 200incorporating decorative material according to embodiments of theinvention. Referring to FIGS. 2A and 2B, a side-view and a top-view of amulti-level solid-core panel 200 are shown. The multi-level solid-corepanel 200 includes a resin and fiberglass substrate 210 thatencapsulates multiple decorative material layers 220, which can renderthe aesthetic material in the layers 220 viewable through at least oneof the top or bottom surfaces of the multi-level solid-core panel 200.

Similar to the solid-core panels 100 and 150 shown and described above,the multi-level solid-core panel 200 can be a flat-rectangular panel, asshown in FIGS. 2A and 2B, or can take on any shape or contour. Forinstance, the multi-level solid-core panel 200 can have exteriorsurfaces formed in any number of shapes. In some embodiments, thesurfaces can be contoured similar to a relief-technique or stamped. Thesurfaces of the multi-level solid-core panel 200 can also have variousfinishes, such as smooth, matte, or textured finishes. Embodiments ofhow the multi-level solid-core panel 200 is produced with these finishesand contours will be described below in greater detail.

The aesthetic or decorative material in the solid-core panel 200 can bearranged in multiple decorative material layers 220. This multiplelayering allows the solid-core panel 200 to have a three-dimensionalvisual image. Although FIG. 2A shows two distinct layers 220, this isnot intended to be limiting, as the multi-level solid-core panel 200 canhave any number of aesthetic material layers.

In some embodiments, the aesthetic material in the multiple decorativematerial layers 220 can be a relatively flat material relative to thetop and bottom surfaces of the solid-core panel 200, for instance,decorative paper, film, fabric or other woven material, tissue, or otherorganic material, while in other embodiments, the aesthetic material canbe any size. For instance, in FIG. 2B the aesthetic material is a groupof flower petals, which can be arranged across the multiple decorativematerial layers 220. Although FIGS. 2A and 2B show the aestheticmaterial as substantially level or parallel with at least one of thesurfaces of the multi-level solid-core panel 200, in some embodiments,the aesthetic material can be positioned or arranged in non-parallelorientation to provide differing aesthetics to the panel or to providevaried functionality.

The resin and fiberglass substrate 210 in the multi-level solid-corepanel 200 is similar to the resin and fiberglass substrate 110 describedabove in FIGS. 1A and 1B. In this multiple level embodiment, thefiberglass can be utilized to define the location of multiple decorativematerial layers 220 and hold the aesthetic material in place duringproduction of the solid-core panel 200. Embodiments of the production ofmulti-level panels will be described below in greater detail.

Surfaces of the resin and fiberglass substrate 110 can include anintegrated protective coating 112 and 114. The protective coating 112and 114 can be a combination of a clear coat, gel coat, polymer,polyurethane-based material and resin, and possibly the fiberglass. Theprotective coating 112 and 114 can provide a rigid surface to thesolid-core panel 100, which reduces bowing or warping of the solid-corepanel 100 and helps prevent scratching, chipping, and fracturing of thesolid-core panel. As will be described below in greater detail, theprotective coating 112 and 114 can be applied prior to or substantiallyconcurrently with the application of the resin, or can be applied afterthe resin has begun curing, for example, in sprayed application.

FIGS. 3A and 3B are block diagrams of an example solid-core panelincorporating decorative material according to embodiments of theinvention. Referring to FIGS. 3A and 3B, a side-view and a top-view of asolid-core panel 300 are shown. The solid-core panel 300 includes aresin and fiberglass substrate 310 that encapsulates decorative material320, which can render the decorative material 320 viewable through atleast one of the top or bottom surfaces of the solid-core panel 300.

Similar to the solid-core panels 100, 150, and 200 shown and describedabove, the solid-core panel 300 can be a flat-rectangular panel, asshown in FIGS. 3A and 3B, or can take on any shape or contour. Forinstance, the solid-core panel 300 can have exterior surfaces formed inany number of shapes. In some embodiments, the surfaces can be contouredsimilar to a relief-technique or stamped. The surfaces of the solid-corepanel 300 can also have various finishes, such as smooth, matte, ortextured finishes. Embodiments of how the solid-core panel 300 isproduced with these finishes and contours will be described below ingreater detail.

The decorative material in the solid-core panel 300 can be arrangedanywhere within the solid-core panel 300, which allows the solid-corepanel 300 to have a three-dimensional visual image. The resin andfiberglass substrate 310 in the solid-core panel 300 is similar to theresin and fiberglass substrates 110 and 210 described above. In thisembodiment, the fiberglass can be utilized to define the location ofdecorative material 320 and hold the decorative material 320 in placeduring production of the solid-core panel 300. Embodiments of theproduction of multi-level panels will be described below in greaterdetail.

Surfaces of the resin and fiberglass substrate 110 can include anintegrated protective coating 112 and 114. The protective coating 112and 114 can be a combination of a polyurethane-based material, a clearcoat polymer, or a gel coat polymer and resin, and possibly thefiberglass. The protective coating 112 and 114 can provide a rigidsurface to the solid-core panel 100, which reduces bowing or warping ofthe solid-core panel 100 and helps prevent scratching, chipping, andfracturing of the solid-core panel. As will be described below ingreater detail, the protective coating 112 and 114 can be applied priorto or substantially concurrently with the application of the resin, orcan be applied after the resin has begun curing, for example, in sprayedapplication.

FIGS. 4-7 are flow diagrams showing example exploded side-views ofsolid-core panels during manufacture according to embodiments of theinvention. Referring to FIG. 4, a flow diagram 400 shows anexploded-side view of the solid-core panel 100 during manufacture. Theflow diagram 400 includes a material section having fiberglass layers410A and 410B located to the top and bottom of the aesthetic materiallayer 420. Although FIG. 4 shows two distinct fiberglass layers 410A and410B, in some embodiments, the material section can include additionalfiberglass layers or the fiberglass layers themselves may comprisemultiple fiberglass layers.

During manufacture, this material section is saturated or impregnatedwith resin 430, which “wets out” both the fiberglass layers 410A and410B and the aesthetic material layer 420. The “wetting out” of thematerial layer section with the resin 430, allows for the creation of asolid-core that encapsulates the aesthetic material layer 420 when theresin 430 cures. As will be described below in greater detail, there areseveral ways of impregnating the material section with resin 430, suchas in a layer-by-layer process or through an injection mold process.

A pair of plates 402 and 404 can be utilized to form the top and bottomsurfaces of the solid-core panel 100 as the combination of the resin 430and the material section cure. Although not shown in FIG. 4, a mold canform the sides of the solid-core panel 100 and control the location ofthe plates 402 and 404. The texture of the plates 402 and 404 candictate the resulting surface in the solid-core panel 100. For instance,the plates 402 and 404 can have smooth, textures, or shaped surfaces,which allows the solid-core panel 100 to have corresponding smooth,textured, or shaped surfaces.

In some embodiments, a protective coating material 403 and 405 isapplied to one or more of the plates 402 and 404, which is allowed tocombine with the resin 430. The protective coating material 403 and 405can be a polyurethane-based product, a clear coat polymer, or a gel coatpolymer that, when integrated with the resin 430, causes the exteriorsurface of the solid-core panel 100 to harden into the protectivecoatings 112 and 114, respectively. In other embodiments, the protectivecoating material 403 and 405 can be applied after the resin 430 hassaturated the material section and has begun to cure, i.e., through aspray-on process.

Referring to FIGS. 5 and 6, flow diagrams 500 and 600 show exploded-sideviews of the solid-core panels 150 and 200 during manufacture. The flowdiagrams 500 and 600 are similar to flow diagram 400, with the followingdifferences. The material section of flow diagram 500 includes multipledecorative material layers 520 interleaved between fiberglass layers510-1 to 510-N. The material section of flow diagram 600 includesmultiple decorative material layers 620 interleaved between fiberglasslayers 610-1 to 610-N.

In flow diagram 500, the decorative or functional material layers 520can be a relatively flat material relative to the top and bottomsurfaces of the solid-core panel 150, for instance, decorative paper,film, fabric or other woven material, tissue, or other organic material,while in other embodiments, the decorative of functional material can beany size. In some embodiments, one or more of the decorative materiallayers 520 can include functional material, such as solar fabric, solarcells, strengthening material, or other electronics.

In flow diagram 600, the decorative material layers 620 can be organicmaterial, such as flower petals, which are spread out over multiplelayers in the solid-core panel 200. In some embodiments, one or more ofthe decorative material layers 620 can include functional material, suchas solar fabric, solar cells, strengthening material, or otherelectronics.

During manufacture, the material section is saturated or impregnatedwith resin 530 or 630, which “wets out” both the fiberglass layers 510-1to 510-N or 610-1 to 610-N and the decorative or functional materiallayers 520 or 620. The “wetting out” of the material section with theresin 530 or 630, allows for the creation of a solid-core thatencapsulates the material layers 520 or 620 when the resin 530 or 630cures.

The fiberglass layers 510-1 to 510-N and 610-1 to 610-N can help holdthe decorative material in place during the application of the resin 530or 630. For example, when utilizing an injection mold process to applythe resin 530 or 630 to the material sections, the resin 530 or 630 isinjected into one side of a mold and vacuumed towards and exit.Typically, any loose material, such as flower petals, paper, or otheraesthetic materials, would shift during the injection process due to theflow and pressure of the resin 530 or 630. By interleaving thedecorative or functional material 520 and 620 with the fiberglass layers510-1 to 610-N or 610-1 to 610-N, the decorative or functional material520 and 620 can substantially maintain its intended position within theresulting solid-core panel 150 or 200.

Referring to FIG. 7, a flow diagram 700 shows an exploded-side view ofthe solid-core panel 300 during manufacture. The flow diagram 700 issimilar to flow diagram 400, with the following differences. Thematerial section of flow diagram 700 includes decorative material 720intertwined or incorporated within fiberglass 710. The incorporation ofthe decorative material 720 with the fiberglass 710 prior to applicationof the resin 730, as opposed to layering described above in FIGS. 4-6,allows for a three-dimensional placement of the decorative (orfunctional) material 720 in the solid-core panel 300.

During manufacture, the material section is saturated or impregnatedwith resin 730, which “wets out” the fiberglass 710 and the decorativematerial 720. The “wetting out” of the material section with the resin730, allows for the creation of a solid-core that encapsulates thedecorative material 720 when the resin 730 cures.

The fiberglass 710 can also hold the decorative (or functional) material720 in place while the resin 730 is applied and curing. For example,when utilizing an injection mold process to apply the resin 730 to thecombination of fiberglass 710 and decorative material 720, the resin 730is injected into one side of a mold and vacuumed towards and exit. Byincorporating the decorative material 720 with the fiberglass 710, thedecorative material 720 can substantially maintain its intended positionwithin the resulting solid-core panel 300.

FIGS. 8-9 are flowcharts illustrating example embodiments for creatingthe solid-core panels according to embodiments of the invention.Referring to FIG. 8, a flowchart 800 describes a process formanufacturing a solid-core panel. In a first block 810 of themanufacturing process, a protective material is applied to multipleplates. The protective material can be a clear or translucent coatingmaterial that, for example, is a polyurethane-based product, a clearcoat polymer, or a gel coat polymer.

In next blocks of the manufacturing process, multiple layers of afiberglass material are arranged between the multiple plates (block 820)and the aesthetic material is interleaved between at least two of thelayers of fiberglass material (block 830). The arrangement of thefiberglass layers and the aesthetic material can define the aestheticsof the resultant solid-core panel, such as the thickness of the panel,the depth and positioning of the aesthetic material in the solid-corepanel, and clarity of the solid-core panel.

In a next block 840 of the manufacturing process, a resin is applied tothe multiple layers of fiberglass material, the aesthetic material, andthe protective material. The resin can be injected into the fiberglassmaterial, the aesthetic material, and the protective material, forexample, in an injection mold process. The resin can impregnate thefiberglass material, the aesthetic material, and the protectivematerial—wetting it out. When the resin combines with the protectivematerial, the resulting combination can form a protective coating thatis integrated into the solid-core panel.

In a next block 850 of the manufacturing process, the combination of theresin, multiple layers of fiberglass material, the aesthetic material,and protective material is allowed to cure between the plates, forming asolid-core panel encapsulating the aesthetic material. As discussedabove, the plates can be smooth, textured, and/or contoured, which formsthe surfaces of the resulting solid-core panel as it cures. The platescan be clamped, pressed, and/or bolted during the curing process to helpensure the surfaces of the resulting solid-core panel are formed withthe desired shape and texture. In some embodiments, during the curingprocess, the use of plates allows the uncured panel to be removed from amold and placed in a cure section or cart, and/or exposed toultra-violet (UV) lights to speed up the curing process, which allowsfor a sped-up reuse of the mold for manufacture of additional panels.

In a next block 860 of the manufacturing process, the plates are removedfrom the solid core panel. In some embodiments, the solid-core panel canbe cut, for example, with a water jet, into customizable sizes.

Referring to FIG. 9, in a first block 910 of another manufacturingprocess, a resin is applied to a first layer of fiberglass material,which impregnates the first layer of fiberglass material with the resin.The first layer of the fiberglass material can be arranged on top of aplate and/or in a mold prior to applying the resin to the fiberglassmaterial.

In the next blocks of the manufacturing process, an aesthetic materialis positioned over the first layer of fiberglass material (block 920)and resin is applied to the aesthetic material, which impregnates theaesthetic material with the resin (block 930). In the next blocks of themanufacturing process, a second layer of fiberglass material is disposedover the aesthetic material (block 940) and resin is applied to thesecond layer of fiberglass material, which impregnates the second layerof fiberglass material with the resin (block 950).

In a next block 960 of the manufacturing process, the resin is allowedto cure, which forms a solid-core panel of the resin, the fiberglassmaterial, and the aesthetic material. In some embodiments, another plateis placed on top of the last layer of fiberglass material impregnatedwith resin. As discussed above, the plates can form the surfaces of thesolid-core panel and help to expedite the manufacturing process.

In a next block 970 of the manufacturing process, a protective materialis applied to the panel during the curing process. The protectivematerial is configured to combine with the resin to form a protectivecoating that is integrated into the soil-core panel. In someembodiments, the protective material can be sprayed on after a period ofcuring has occurred.

One of skill in the art will recognize that the concepts taught hereincan be tailored to a particular application in many other ways. Inparticular, those skilled in the art will recognize that the illustratedembodiments are but one of many alternative implementations that willbecome apparent upon reading this disclosure.

The preceding embodiments are examples. Although the specification mayrefer to “an”, “one”, “another”, or “some” embodiment(s) in severallocations, this does not necessarily mean that each such reference is tothe same embodiment(s), or that the feature only applies to a singleembodiment.

1. A panel comprising: a fiberglass substrate encapsulating an aestheticmaterial, wherein the fiberglass substrate and the aesthetic materialare both impregnated with resin to form a solid-core of the panel. 2.The panel of claim 1, wherein the aesthetic material comprises multiplelevels within the fiberglass substrate.
 3. The panel of claim 1, whereinthe aesthetic material includes at least one of a solar cell device or asolar fabric.
 4. The panel of claim 1, further comprising a protectivecoating located at one or more surfaces of the panel, wherein theprotective coating is integrated with the resin residing at one or moresurfaces of the panel.
 5. The panel of claim 4, wherein the protectivecoating is a combination of the resin and at least one of apolyurethane-based product, a clear coat polymer, or a gel coat polymer.6. The panel of claim 1, wherein the aesthetic material is metal or adecorative organic material including at least one of a paper, tissue,fabric, or plant material.
 7. The panel of claim 1, wherein thefiberglass substrate encapsulates the aesthetic material in anorientation that is non-parallel to surfaces of the panel.